1NZ-FE STARTING – STARTING SYSTEM (for 0.

8 kW Type) ST–1

STARTING SYSTEM (for 0.8 kW Type)

1NZ-FE STARTING
ENGINE

PARTS LOCATION

ST

STARTER

INTEGRATION RELAY STARTER RELAY

A119210E01
 ST–2 1NZ-FE STARTING – STARTING SYSTEM (for 0.8 kW Type)

ST

ACC CUT
RELAY

IGNITION RELAY

A119205E01
 1NZ-FE STARTING – STARTING SYSTEM (for 0.8 kW Type) ST–3

SYSTEM DIAGRAM

25 A AM1
IG

ACC
AM1
Main Body ECU
IG

AM2
Ignition Switch STSW

Diode
7.5 IGN
ST-1

Integration
7.5 A ACC
15 A
AM2
ACCR
ST
ACC CUT

STA
30 A ST

ST
STAR
 Clutch Start
Switch

 Park Neutral
Start Switch

Battery

Starter

 for Manual Transaxle ECM

 for Automatic Transaxle
A119143E03
 ST–4 1NZ-FE STARTING – STARTING SYSTEM (for 1.6 kW Type)

STARTING SYSTEM (for 1.6 kW Type)

1NZ-FE STARTING
ENGINE

PARTS LOCATION

ST

STARTER

INTEGRATION RELAY STARTER RELAY

A119210E01
1NZ-FE STARTING – STARTING SYSTEM (for 1.6 kW Type) ST–5

ST

ACC CUT
RELAY

IGNITION RELAY

A119205E01
 ST–6 1NZ-FE STARTING – STARTING SYSTEM (for 1.6 kW Type)

SYSTEM DIAGRAM

25 A AM1
IG

ACC
AM1
Main Body ECU
IG

AM2
Ignition Switch STSW

Diode
7.5 IGN
ST-1

Integration
7.5 A ACC
15 A
AM2
ACCR
ST
ACC CUT

STA
30 A ST

ST
STAR
 Clutch Start
Switch

 Park Neutral
Start Switch

Battery

Starter

 for Manual Transaxle ECM

 for Automatic Transaxle
A119143E03
 1NZ-FE STARTING – STARTER (for 0.8 kW Type) ST–7

STARTER (for 0.8 kW Type)

1NZ-FE STARTING
ENGINE

COMPONENTS

9.8 (100, 87 in.*lbf)

ST

STARTER ASSEMBLY
37 (377, 27)
37 (377, 27)

FLYWHEEL HOUSING SIDE COVER

N*m (kgf*cm, ft*lbf) : Specified torque

A119211E02
 ST–8 1NZ-FE STARTING – STARTER (for 0.8 kW Type)

8.3 (85, 73 in.*lbf)

9.8 (100, 87 in.*lbf)

MAGNET STARTER SWITCH ASSEMBLY

STOP COLLAR

STARTER HOUSING
SNAP RING
DRIVE LEVER
STARTER CLUTCH SUB-ASSEMBLY

SHOCK ABSORBER

ST STARTER YOKE
ASSEMBLY

STARTER ARMATURE
1.5 (15, 13 in.*lbf)
ASSEMBLY
5.9 (60, 52 in.*lbf)

STARTER BRUSH
HOLDER ASSEMBLY

COMMUTATOR
END FRAME

N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Apply grease

A104524E06
1NZ-FE STARTING – STARTER (for 0.8 kW Type) ST–9

REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
2. REMOVE FLYWHEEL HOUSING SIDE COVER
(a) Disengage the claw while pushing it upward and
remove the flywheel housing side cover.

Claw
A104497E01

3. REMOVE STARTER ASSEMBLY

(a) Remove the terminal cap.
(b) Remove the nut and remove terminal 30.
(c) Disconnect the connector.
(d) Remove the 2 bolts and remove the starter
assembly.

A104498

DISASSEMBLY
1. REMOVE MAGNET STARTER SWITCH ASSEMBLY ST
(a) Remove the nut, and disconnect the lead wire from
the magnet starter switch assembly terminal.

A062929

(b) Loosen the 2 nuts holding the magnet starter switch

assembly onto the starter housing.

A062930
 ST–10 1NZ-FE STARTING – STARTER (for 0.8 kW Type)

(c) Pull the magnet starter switch assembly and while

lifting the front part of the magnet starter switch
assembly, release the plunger hook from the driver
lever, then remove the magnet starter switch
assembly.

ST00742

2. REMOVE STARTER YOKE ASSEMBLY

(a) Remove the 2 through bolts, and pull out the field
frame together with the armature.

A034019

3. REMOVE STARTER BRUSH HOLDER ASSEMBLY

(a) Remove the 2 screws and the commutator end
frame, and hold down the lead wire while releasing
the commutator end frame.
NOTICE:
ST To avoid interference between the brush holder
and the dust protector, pull the commutator end
frame away at an angle.

ST00728

(b) Using a screwdriver, hold the spring back and

disconnect the brush holder.
(c) Disconnect the 4 brushes, and remove the brush
holder.
4. REMOVE STARTER ARMATURE ASSEMBLY

A064784

5. REMOVE STARTER CLUTCH SUB-ASSEMBLY

Starter Housing Drive Lever
(a) Remove the drive lever and starter clutch with shock
absorber from starter housing.

Starter Clutch with

Shock Absorber

ST00741E01
1NZ-FE STARTING – STARTER (for 0.8 kW Type) ST–11

(b) Using a screwdriver, tap in the stop collar toward the

starter clutch.

A033589

(c) Using a screwdriver, pry off the snap ring.

(d) Remove the stop collar and starter clutch from the
planetary shaft.

A033590

ST
 ST–12 1NZ-FE STARTING – STARTER (for 0.8 kW Type)

INSPECTION
1. INSPECT STARTER ASSEMBLY
NOTICE:
Perform each of the following tests within 3 to 5
seconds.
(a) Perform pull-in test.
(1) Disconnect the field coil lead wire from terminal
C.
(2) Connect the battery to the starter magnetic
switch as shown in the illustration and check
Body Terminal that the pinion gear is extended.
C

Terminal 50
A064944E01

(b) Perform holding test.

(1) Check that the pinion gear does not return
Body Terminal inward after the cable of terminal C is
C disconnected.

ST Terminal 50
A064945E01

(c) Inspect the clutch pinion gear return.

(1) Disconnect the negative (-) lead from the
Body Terminal starter body and move the pinion gear toward
C the armature.
(d) Perform the operation test without load.
(1) Connect the field coil lead wire to terminal C.
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
(2) Clamp the starter in a vise.
Terminal 50
A064946E01
 1NZ-FE STARTING – STARTER (for 0.8 kW Type) ST–13

(3) Connect the battery and ammeter to the starter

as shown in the illustration.
Ammeter (4) Check that the ammeter indicates the specified
current.
Standard current:
90A or less at 11.5V
Body

Terminal 50

Terminal 30

A117813E01

2. INSPECT STARTER ARMATURE ASSEMBLY

(a) Check the commutator for open circuits.
(1) Using an ohmmeter, check the resistance
between the segments of the commutator.
Standard resistance:
Below 1 Ω
If the result is not as specified, replace the
Commutator
starter armature assembly.

A104566E01

(b) Check the commutator for ground. ST

(1) Using an ohmmeter, check the resistance
between the commutator and the armature
core.
Standard resistance:
Armature 10 kΩ or higher
If the result is not as specified, replace the
Commutator starter armature assembly.
(c) Check the commutator surface for dirt and burns.
A104565E01 If the surface is dirty or burnt, restore it with
sandpaper (No. 400) or a lathe.
(d) Check for the commutator cirumference runout.
(1) Place the commutator on V-blocks.
(2) Using a dial indicator, measure the
cirumference runout.
Maximum runout:
0.05 mm (0.0020 in.)
If the runout is greater than the maximum,
replace the starter armature assembly.

A037025
 ST–14 1NZ-FE STARTING – STARTER (for 0.8 kW Type)

(e) Using vernier calipers, measure the commutator

diameter.
Standard diameter:
28.0 mm (1.1024 in.)
Minimum diameter:
27.0 mm (1.0630 in.)
If the diameter is less than the minimum, replace the
starter armature assembly.

A033574E01

(f) Check that the undercut portion between the

segments is free of foreign matter and measure its
depth.
Standard undercut depth:
0.6 mm (0.0236 in.)
Minimum undercut depth:
0.2 mm (0.0079 in.)
If the undercut depth is less than the minimum,
adjust it with a hacksaw blade.
A033575E01

3. INSPECT STARTER YOKE ASSEMBLY

Brush
(a) Using an ohmmeter, check the resistance between
terminal C and the field coil brush lead.
Standard resistance:
Below 1 Ω
Terminal C
ST If the result is not as specified, replace the starter
yoke assembly.

A064787E01

(b) Using an ohmmeter, check the resistance between

Brush
the brush lead and the starter yoke.
Standard resistance:
10 kΩ or higher
If the result is not as specified, replace the starter
yoke assembly.
Starter Yoke

A064788E01

4. INSPECT BRUSH
(a) Using vernier calipers, measure the brush length.
Standard length:
14 mm (0.5511 in.)
Minimum length:
9 mm (0.3543 in.)
If the length is less than the minimum, replace the
starter brush holder assembly and the starter yoke
assembly.
A037017
 1NZ-FE STARTING – STARTER (for 0.8 kW Type) ST–15

5. INSPECT STARTER BRUSH HOLDER ASSEMBLY

(a) Using an ohmmeter, measure the resistance
between the positive (+) and negative (-) brush
holders.
Standard resistance:
10 kΩ or higher
If the result is not as specified, replace the starter
brush holder assembly.

A037020E01

6. INSPECT STARTER CLUTCH SUB-ASSEMBLY

Free (a) Hold the starter clutch and rotate the pinion gear
clockwise, and check that it turns freely. Try to rotate
the pinion gear counterclockwise and check that it
locks.
If necessary, replace the starter clutch sub-
assembly.
Lock

A033579E01

7. INSPECT MAGNET STARTER SWITCH ASSEMBLY

(a) Check the plunger.
(1) Push in the plunger and check that it returns
quickly to its original position.
If necessary, replace the magnet starter switch
assembly. ST

A033580

(b) Check the pull-in coil for open circuits.

(1) Using an ohmmeter, check the resistance
Terminal
%┵ሶ C between terminals 50 and C.
Standard resistance:
Below 1 Ω
If the result is not as specified, replace the
magnet starter switch assembly.

Terminal
┵ሶ 50
A104569E01

(c) Check whether the holding coil has open circuit.

(1) Using an ohmmeter, check the resistance
between terminal 50 and the switch body.
Standard resistance:
Below 2 Ω
If the result is not as specified, replace the
magnet starter switch assembly.

Terminal
┵ሶ
50
A104570E01
 ST–16 1NZ-FE STARTING – STARTER (for 0.8 kW Type)

REASSEMBLY
1. INSTALL STARTER CLUTCH SUB-ASSEMBLY
(a) Apply grease to the bushing and spline of the starter
clutch and stop collar.
(b) Place the starter clutch and stop collar on the
planetary shaft.
(c) Apply grease to a new snap ring, and install it onto
the planetary shaft groove.

Apply grease
A033607E01

(d) Using a vise, compress the snap ring.

A033608

ST (e) Hold the starter clutch, tap the planetary shaft and
install the stop collar onto the snap ring with a
plastic-faced hammer.

A033587

(f) Apply grease to the drive lever which is in contact

Drive Lever
with the starter pivot part of the drive lever.
Starter (g) Install the drive lever onto the starter clutch.
Clutch

Apply grease
A064789E02
 1NZ-FE STARTING – STARTER (for 0.8 kW Type) ST–17

(h) Align the protrusion of the shock absorber with the

Starter cutout of the starter housing and install it.
Housing Cutout
Protrusion
2. INSTALL STARTER ARMATURE ASSEMBLY
3. INSTALL STARTER BRUSH HOLDER ASSEMBLY
(a) Install the brush holder.

Shock Absorber
A032702E02

(b) Using a screwdriver, hold the brush spring back,

and install the 4 brushes into the brush holder.
(c) Apply turbine oil with additives to the bearing of the
end frame.

A064784

(d) Install the end frame with 2 new screws.

Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf)
NOTICE:
To avoid interference between the brush holder
and the dust protector, push the commutator
end frame away at an angle. ST

ST00728

4. INSTALL STARTER YOKE ASSEMBLY

Protrusion (a) Align the cutout of the field frame with the protrusion
of the shock absorber.
Cutout

Shock Absorber
A032703E02

(b) Install the field frame and the armature assembly

with the 2 through bolts.
Torque: 5.9 N*m (60 kgf*cm, 52 in.*lbf)

A034019
 ST–18 1NZ-FE STARTING – STARTER (for 0.8 kW Type)

5. INSTALL MAGNET STARTER SWITCH ASSEMBLY

(a) Hang the plunger of the magnet starter switch
assembly onto the driver lever from the upper side.

ST00742

(b) Install the magnet starter switch assembly with the 2

nuts.
Torque: 8.3 N*m (85 kgf*cm, 73 in.*lbf)

A064791

(c) Connect the lead wire to the terminal with the nut.
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)

ST

A064790

INSTALLATION
1. INSTALL STARTER ASSEMBLY
(a) Install the starter assembly with the 2 bolts.
Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)
(b) Connect the connector.
(c) Connect terminal 30 with the nut.
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
(d) Close the terminal cap.
A104498

2. INSTALL FLYWHEEL HOUSING SIDE COVER

(a) Insert the protruding portion into the end of the
cylinder block and while pushing it along the
cylinder block, fit the 2 claws into the cylinder block.
NOTICE:
• Make sure that the claw makes a click sound,
indicating that it fits tightly.
• Replace the claw with a new one if it does not
Claws fit tightly or is deformed.
A104497E03
1NZ-FE STARTING – STARTER (for 0.8 kW Type) ST–19

3. CONNECT CABLE TO NEGATIVE BATTERY

TERMINAL
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)

ST
 1NZ-FE STARTING – STARTER (for 1.6 kW Type) ST–19

STARTER (for 1.6 kW Type)

1NZ-FE STARTING
ENGINE

COMPONENTS

9.8 (100, 87 in.*lbf)

ST

STARTER ASSEMBLY
37 (377, 27)
37 (377, 27)

FLYWHEEL HOUSING SIDE COVER

N*m (kgf*cm, ft*lbf) : Specified torque

A119211E03
 ST–20 1NZ-FE STARTING – STARTER (for 1.6 kW Type)

STARTER YOKE ASSEMBLY

STARTER ARMATURE ASSEMBLY

STARTER COMMUTATOR
END FRAME ASSEMBLY

6.0 (61, 53 in.*lbf)

WASHER
SNAP RING

STARTER COMMUTATOR END

MAGNET SWITCH BODY FRAME COVER

ST
7.5 (76, 66 in.*lbf)

10 (102, 7.4)

STARTER DRIVE LEVER

SET PIN

STARTER DRIVE HOUSING ASSEMBLY

STARTER CENTER BEARING

CLUTCH SUB-ASSEMBLY
STARTER PLANETARY GEAR

STARTER ARMATURE PLATE

N*m (kgf*cm, ft.*lbf) : Specified torque Apply grease Non-reusable part

A117346E03
1NZ-FE STARTING – STARTER (for 1.6 kW Type) ST–21

REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
2. REMOVE FLYWHEEL HOUSING SIDE COVER
(a) Disengage the claw while pushing it upward and
remove the flywheel housing side cover.

A119129

3. REMOVE STARTER ASSEMBLY

(a) Remove the terminal cap.
(b) Remove the nut and remove terminal 30.
(c) Disconnect the connector.
(d) Remove the 2 bolts and remove the starter
assembly.

A119130

DISASSEMBLY
1. REMOVE MAGNET SWITCH BODY ST
(a) Remove the nut, and disconnect the lead wire from
the magnet switch body.

A081590E01

(b) Remove the 2 screws holding the magnet switch

body onto the starter drive housing assembly.
(c) Remove the magnet switch body.
(d) Remove the return spring and the plunger.

A082688E01
 ST–22 1NZ-FE STARTING – STARTER (for 1.6 kW Type)

2. REMOVE STARTER YOKE ASSEMBLY

(a) Remove the 2 through bolts, and pull out the starter
yoke assembly and starter commutator end frame
assembly together.

A082689E01

(b) Remove the starter yoke assembly from the starter

Starter Yoke Assembly
commutator end frame assembly.

A083800E02

3. REMOVE STARTER COMMUTATOR END FRAME

Starter Commutator
COVER
End Frame Cover
(a) Using a screwdriver, remove the starter commutator
end frame cover.

ST

A083801E02

4. REMOVE STARTER ARMATURE ASSEMBLY

(a) Using snap ring pliers, remove the snap ring and the
plate washer.
(b) Remove the starter armature assembly from the
commutator end frame assembly.

A073993E04

5. REMOVE STARTER ARMATURE PLATE

Starter Armature
(a) Remove the starter armature plate from the starter
Plate
yoke assembly.

A083803E02
 1NZ-FE STARTING – STARTER (for 1.6 kW Type) ST–23

6. REMOVE STARTER PLANETARY GEAR

Starter (a) Remove the 3 planetary gears.
Planetary
Gear

A082690E02

7. REMOVE STARTER CENTER BEARING CLUTCH

Drive Lever
Set Pin
SUB-ASSEMBLY
(a) Remove the starter center bearing clutch sub-
assembly with drive lever set pin from the starter
Starter Center
drive housing assembly.
Bearing Clutch
(b) Remove the drive lever set pin from the starter
Sub-Assembly
center bearing clutch sub-assembly.

A073990E02

ST
 ST–24 1NZ-FE STARTING – STARTER (for 1.6 kW Type)

INSPECTION
1. INSPECT STARTER ASSEMBLY
CAUTION:
Perform each of the following tests within 3 to 5
seconds to prevent the coil from burning out.

Terminal 30

Terminal 50

Terminal C

A112753E02

(a) Perform pull-in / holding test.

ST Operation

A112754E01

(1) Disconnect the lead wire from terminal C.

(2) Connect the battery to the magnet switch body
as shown in the illustration. Then check that the
clutch pinion gear moves outward.
If the result is not as specified, replace the
magnet switch body.
(3) Disconnect the negative (-) lead from terminal
C. Check that the pinion gear remains
extended.
If the result is not as specified, replace the
magnet switch body.
 1NZ-FE STARTING – STARTER (for 1.6 kW Type) ST–25

Disconnect

Terminal C

A112755E02

(4) Disconnect the negative (-) lead from the

starter body. Check that the clutch pinion gear
returns inward.
If the result is not as specified, replace the
magnet switch body.

Operation

ST

Disconnect

A112756E01

(b) Perform operation test without load.

(1) Connect the lead wire to terminal C.
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
(2) Clamp the starter in a vise.
(3) Connect the battery and ammeter to the starter
as shown in the illustration.
(4) Check that the starter rotates smoothly while
the pinion gear is extended. Then measure the
current.
Standard current:
90A or less at 11.5V
If the result is not as specified, replace the
magnet switch body.
 ST–26 1NZ-FE STARTING – STARTER (for 1.6 kW Type)

Terminal 50

Terminal 30 Connect

A112757E02

2. INSPECT STARTER ARMATURE ASSEMBLY

(a) Inspect the commutator for open circuits.
Segment (1) Using an ohmmeter, check the resistance
between the segments of the commutator.
Standard resistance:
ST 1Ω or lower
Segment If the result is not as specified, replace the
starter armature assembly.
Commutator
A073983E06

(b) Inspect the commutator for ground.

(1) Using an ohmmeter, check the resistance
between the commutator and armature coil
Armature
core.
Standard resistance:
Commutaror 10 kΩ or higher
If the result is not as specified, replace the
starter armature assembly.
Segment
Coil core (c) Inspect the commutator surface for dirt and burns.
A073984E05 If the surface is dirty or burnt, restore it with 400-grit
sandpaper.
(d) Using vernier calipers, measure the commutator
length.
Standard length:
3.1 mm (0.122 in.)
Maximum length:
Lenght
3.8 mm (0.150 in.)
If the length is greater than the maximum, replace
the armature assembly.

A058584E05
 1NZ-FE STARTING – STARTER (for 1.6 kW Type) ST–27

3. INSPECT STARTER COMMUTATOR END FRAME

ASSEMBLY
(a) Using vernier calipers, measure the brush length.
Standard length:
9.0 mm (0.354 in.)
Minimum length:
Lenght 4.0 mm (0.158 in.)
If the length is less than the minimum, replace the
starter commutator end frame assembly.
A076677E03

(b) Inspect the brush holder.

(1) Using an ohmmeter, check the resistance
between the positive (+) and negative (-)
brushes.
Standard resistance:
10 kΩ or higher
If the result is not as specified, replace the
starter commutator end frame assembly.
4. INSPECT STARTER CENTER BEARING CLUTCH
A073986E02
SUB-ASSEMBLY
(a) Inspect the gear teeth on the planetary gear, internal
gear and starter clutch for wear and damage.
If damaged, replace the starter planetary gear or
starter center bearing clutch sub-assembly. Also
check the starter planetary gear for wear or
damage.
(b) Inspect the starter clutch.
ST
Free (1) Rotate the clutch pinion gear clockwise and
check that it turns freely. Try to rotate the clutch
pinion gear counterclockwise and check that it
locks.
If necessary, replace the starter center bearing
clutch sub-assembly.
Lock
A073987E03

5. INSPECT MAGNET SWITCH BODY

(a) Inspect the plunger.
(1) Push in the plunger and check that it returns
quickly to its original position.
If necessary, replace the magnet switch body.

A058586E01
 ST–28 1NZ-FE STARTING – STARTER (for 1.6 kW Type)

(b) Inspect the pull-in coil for open circuits.

Terminal C (1) Using an ohmmeter, check the resistance
between terminals 50 and C.
Standard resistance:
1Ω or lower
If the result is not as specified, replace the
magnet switch body.

Terminal 50
A082691E03

(c) Check whether the holding coil has an open circuit.

(1) Using an ohmmeter, check the resistance
between terminal 50 and the magnet switch
body.
Standard resistance:
2Ω or lower
If the result is not as specified, replace the
magnet switch body.
Terminal 50
A082692E03

REASSEMBLY
1. INSTALL STARTER CENTER BEARING CLUTCH
SUB-ASSEMBLY
(a) Apply grease to the drive lever set pin which is in
contact with the starter pivot part of the drive lever
ST set pin.

Apply grease
A124187E01

(b) Install the drive lever set pin into the starter center
bearing clutch sub-assembly.

Starter Center
Starter Drive Bearing Clutch
Lever Set Pin Sub-Assembly

A084665E03
 1NZ-FE STARTING – STARTER (for 1.6 kW Type) ST–29

(c) Install the starter center bearing clutch sub-

assembly together with the starter drive lever set pin
into the starter drive housing assembly.

A083805E01

2. INSTALL STARTER PLANETARY GEAR

Starter (a) Apply grease to the planetary gears and pin parts of
Planetary the planetary shaft.
Gear
(b) Install the 3 planetary gears.

Apply grease
A082690E03

3. INSTALL STARTER ARMATURE ASSEMBLY

(a) Apply grease to the washer plate and the armature
shaft.
(b) Install the armature shaft onto the starter
commutator end frame assembly.
(c) Using snap ring pliers, install the plate washer and a
new snap ring.
ST

A073993E04

(d) Using vernier calipers, measure the snap ring.

Maximum length:
Length
5.0 mm (0.197 in.)
If the length is greater than the maximum, replace
the snap ring.

A058810E01

4. INSTALL STARTER COMMUTATOR END FRAME

Starter Connector
COVER
End Frame Cover
(a) Install the starter commutator end frame cover onto
the starter commutator end frame assembly.

A084616E02
 ST–30 1NZ-FE STARTING – STARTER (for 1.6 kW Type)

5. INSTALL STARTER ARMATURE PLATE

key
(a) Insert the starter armature plate into the starter yoke
keyway assembly.
(b) Align the cutout of the plate with the inside
protrusion of the starter yoke assembly, and install
the plate.

Starter Armature Plate

A073991E15

6. INSTALL STARTER COMMUTATOR END FRAME

ASSEMBLY
Rubber
(a) Align the starter commutator rubber end frame with
the cutout of the starter yoke assembly.
(b) Install the starter yoke assembly onto the starter
commutator end frame assembly.
Cutout

A058587E01

7. INSTALL STARTER YOKE ASSEMBLY

(a) Align the key located on the starter yoke assembly
with the keyway of the starter drive housing
assembly.
key

ST
keyway

A082693E01

(b) Install the starter yoke assembly with the 2 through

bolts.
Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)

A082689E01

8. INSTALL MAGNET SWITCH BODY

(a) Apply grease to the plunger and the hook.
(b) Put the plunger hook of the magnet switch body on
the starter drive lever set pin.
(c) Install the plunger and the return spring as shown in
the illustration.

A082694E01
1NZ-FE STARTING – STARTER (for 1.6 kW Type) ST–31

(d) Install the magnet switch body with the 2 screws.

Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)

A082688E01

(e) Connect the lead wire to the terminal C with the nut.
Torque: 10 N*m (102 kgf*cm, 7.4 ft.*lbf)

A081590E02

INSTALLATION
1. INSTALL STARTER ASSEMBLY
(a) Install the starter assembly with the 2 bolts.
Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)
(b) Connect the connector.
(c) Connect terminal 30 with the nut. ST
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
(d) Close the terminal cap.
A119130

2. INSTALL FLYWHEEL HOUSING SIDE COVER

(a) Insert the protruding portion into the end of the
cylinder block and while pushing it along the
cylinder block, fit the 2 claws into the cylinder block.
NOTICE:
• Make sure that the claw makes a click sound,
indicating that it fits tightly.
• Replace the claw with a new one if it does not
Claws fit tightly or is deformed.
A119129E01
3. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
 ST–32 1NZ-FE STARTING – STARTER RELAY

STARTER RELAY
ON-VEHICLE INSPECTION
1. INSPECT STARTER RELAY ASSEMBLY
(a) Check the resistance.
(1) Using an ohmmeter, measure the resistance
between the terminals.
Standard resistance
E034090E03
Tester Connection Specified Condition
Below 1 Ω (when battery voltage
3-5 applied to terminals 1 and 2)
10 kΩ or higher

If the result is not as specified, replace the

relay.

ST
 1NZ-FE STARTING – ACC CUT RELAY ST–33

ACC CUT RELAY

1NZ-FE STARTING
ENGINE

COMPONENTS

ST

ACC CUT RELAY

INSTRUMENT PANEL BOX

A115434E02
 ST–34 1NZ-FE STARTING – ACC CUT RELAY

REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
2. REMOVE INSTRUMENT PANEL BOX (See page IP-70)
3. REMOVE ACC CUT RELAY
(a) Remove the ACC cut relay.

A115436

INSPECTION
1. INSPECT ACC CUT RELAY
(a) Check the resistance.
(1) Using an ohmmeter, measure the resistance
between the terminals.
Standard resistence
Tester Connection Specified Condition
Below 1 Ω
A030519E02 3-4 10 kΩ or higher (when battery
voltage applied to terminals 1 and 2)

ST 3-5
Below 1 Ω (when battery voltage
applied to terminals 1 and 2)
10 kΩ or higher

If the result is not as specified, replace the

relay.
INSTALLATION
1. INSTALL ACC CUT RELAY
(a) Install the ACC cut relay.
2. INSTALL INSTRUMENT PANEL BOX (See page IP-78)
3. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
A115436
 1NZ-FE STARTING – INTEGRATION RELAY ST–35

INTEGRATION RELAY
1NZ-FE STARTING
ENGINE

COMPONENTS

RELAY BLOCK COVER NO. 1

INTEGRATION RELAY

ST

A115401E01
 ST–36 1NZ-FE STARTING – INTEGRATION RELAY

REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
2. REMOVE RELAY BLOCK COVER NO. 1
3. REMOVE INTEGRATION RELAY
(a) Using a screwdriver with its tip wrapped in
protective tape, disengage the 2 claws and
disconnect the integration relay.
(b) Disconnect the 3 connectors.

A115400

ST Integration Relay INSPECTION

Fuse Side: 1. INSPECT INTEGRATION RELAY
(a) Inspect the AM2 (15A) fuse.
1 (1) Disconnect the fuse. Using an ohmmeter,
2 measure the resistance of the fuse.
AM2 (15A) Fuse Standard resistance
Tester Connection Specified condition
Connector Side:
1-2 Below 1 Ω

(b) Inspect the IG2 relay.

(1) Using an ohmmeter, measure the resistance
between the terminals.
Standard resistance
C B A
Tester Connection Specified condition
A107023E05
B1 - C1 Below 1 Ω
Below 1 Ω
(when battery voltage applied to
B4 - C1 terminals 1 and 2)
10 kΩ or higher

NOTICE:
While using the battery for the inspection,
do not bring the positive and negative tester
probes too close to each other as a short
circuit may occur.
1NZ-FE STARTING – INTEGRATION RELAY ST–37

INSTALLATION
1. INSTALL INTEGRATION RELAY
(a) Connect the 3 connectors.
(b) Attach the integration relay to the engine room relay
block.
2. INSTALL RELAY BLOCK COVER NO. 1
3. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)

ST
 ST–38 1NZ-FE STARTING – IGNITION RELAY

IGNITION RELAY
1NZ-FE STARTING
ENGINE

COMPONENTS

ST

IGNITION RELAY
INSTRUMENT PANEL BOX

A115435E01
1NZ-FE STARTING – IGNITION RELAY ST–39

REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
2. REMOVE INSTRUMENT PANEL BOX (See page IP-70)
3. REMOVE IGNITION RELAY
(a) Remove the ignition relay.

A115437

INSPECTION
1. INSPECT IGNITION RELAY
(a) Check the resistance.
(1) Using an ohmmeter, measure the resistance
between the terminals.
Standard resistance
Tester Connection Specified Condition
Below 1 Ω (when battery voltage
A032779E02 3-5 applied to terminals 1 and 2)
10 kΩ or higher

If the result is not as specified, replace the ST

relay.
INSTALLATION
1. INSTALL IGNITION RELAY
(a) Install the ignition relay.
2. INSTALL INSTRUMENT PANEL BOX (See page IP-78)
3. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
A115437
 ST–40 1NZ-FE STARTING – IGNITION SWITCH

IGNITION SWITCH
1NZ-FE STARTING
ENGINE

COMPONENTS

STEERING COLUMN
UPPER COVER

IGNITION OR STARTER
SWITCH ASSEMBLY
STEERING COLUMN
LOWER COVER

E107141E01

ST
1NZ-FE STARTING – IGNITION SWITCH ST–41

REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
2. REMOVE STEERING COLUMN COVER
(a) Turn the steering wheel to the right and remove the
screw indicated in the illustration.

E107137

(b) Turn the steering wheel to the left and remove the
screw indicated in the illustration.

A119195

(c) Remove the screw indicated in the illustration and

remove the steering column cover. ST

E107139

3. REMOVE IGNITION OR STARTER SWITCH

ASSEMBLY
(a) Disconnect the connector.
(b) Disengage the 2 claws and remove the ignition or
starter switch assembly.

A119192E01
 ST–42 1NZ-FE STARTING – IGNITION SWITCH

INSPECTION
LOCK 1. INSPECT IGNITION OR STARTER SWITCH
ASSEMBLY
ACC (a) Check the resistance.
(1) Using an ohmmeter, measure the resistance
ON between the terminals.
Standard resistance
Condition Tester Connection Standard
START
LOCK Between all terminals 10 kΩ or higher
ACC 2-4 Below 1 Ω
1-2-4
ON Below 1 Ω
5-6
1-3-4
START Below 1 Ω
5-6-7

4 3 2 1
7 6 5

A119190E01

INSTALLATION
1. INSTALL IGNITION OR STARTER SWITCH
ASSEMBLY
(a) Engage the 2 claws and install the ignition or starter
ST switch assembly.
(b) Connect the connector.

A119192E01

2. INSTALL STEERING COLUMN COVER

(a) Install the screw indicated in the illustration.

E107139

(b) Turn the steering wheel to the left and install the
screw indicated in the illustration.

A119195
1NZ-FE STARTING – IGNITION SWITCH ST–43

(c) Turn the steering wheel to the right, and install the
screw indicated in the illustration.
3. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)

E107137

ST